General Information:
Includes general vehicle information, specifications, and diagnostic procedures.
Maintenance:
Routine maintenance, service schedules, and fluid specifications.
Engine Mechanical:
Detailed procedures for engine disassembly, assembly, inspection, and repair.
Engine Lubrication Cooling:
Oil system, oil pump, filter, oil cooler, water pump, radiator, thermostat, cooling fan operation, and diagnosis.
Engine Fuel Emission:
Fuel delivery, injectors, fuel pump, evaporative emission control (EVAP), secondary air injection, and exhaust gas recirculation (EGR).
Accelerator Control:
Throttle body, accelerator pedal, and linkage (mechanical or electronic throttle control).
Fuel Exhaust Systems:
Fuel tank, fuel lines, fuel filter, exhaust manifolds, catalytic converter, muffler, and tailpipe.
Clutch:
Clutch disc, pressure plate, release bearing, clutch master cylinder, slave cylinder, and hydraulic lines.
Manual Transmission:
Gearbox components, shift mechanism, bearings, seals, and lubrication.
Automatic Transmission:
Transmission operation, valve body, torque converter, planetary gears, electronic controls, and fluid.
Propeller Shaft Differential:
Driveshaft, universal joints, constant velocity (CV) joints, and differential carrier assembly.
Front Axle:
Hubs, bearings, steering knuckles, and drive axles (if applicable).
Rear Axle:
Axle housing, differential, drive shafts, and wheel bearings.
Front Suspension:
MacPherson struts, control arms, ball joints, tie rod ends, sway bar, and bushings.
Rear Suspension:
Beam axle, trailing arms, shock absorbers, coil springs, and bushings.
Brake System:
Front and rear brake calipers, rotors, pads, brake lines, master cylinder, power booster, ABS components, and parking brake.
Steering System:
Steering column, steering rack (power or manual), power steering pump, fluid, and tie rods.
Restraint System:
Airbag system components, seat belts, SRS module, and related wiring.
Body And Trim:
Body panel removal and installation, interior trim, door mechanisms, glass, and weatherstripping.
Heater Air Conditioner:
HVAC system components, blower motor, evaporator, condenser, refrigerant, cabin filter, and controls.
Electrical System:
Battery, charging system, starter, ignition system, lighting, fuses, relays, wiring diagrams, and ECU diagnostics.
Etc:
Covers various other systems and components as applicable to vehicle maintenance and repair.
Diagnostics:
Comprehensive diagnostic procedures, including symptom identification and troubleshooting charts.
Repair Procedures:
Step-by-step instructions for component removal, installation, and repair.
Technical Data:
Torque specifications, clearances, tolerances, and electrical values.
Depth:
Comprehensive, technician-level detail covering all aspects of maintenance, diagnosis, and repair.
Service Intervals General
Oil Change Recommendation:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first, under normal driving conditions. Severe duty may require more frequent changes.
Air Filter Replacement:
Inspect every 15,000 miles (24,000 km), replace as needed. Typically recommended every 30,000 miles (48,000 km).
Spark Plug Replacement:
Refer to specific engine and spark plug type (e.g., iridium plugs may have longer intervals of 100,000 miles).
Engine Oil Specification:
SAE 5W-30 for most models. Check owner's manual or manual for specific engine requirements (e.g., MS-6395).
Coolant Specification:
Chrysler Formula 50/50 antifreeze/coolant (HOAT - Hybrid Organic Acid Technology) meeting MS-9769.
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid.
Common Wear Items:
Suspension components (struts, ball joints, control arm bushings), brake wear, exhaust system components, and potential for oil leaks.
Electrical Gremlins:
Some owners have reported intermittent electrical issues, often related to ground points or specific sensor failures, which this manual would help diagnose.
Engine Specific Notes:
The 2.4L engine, particularly the turbo variant, can be prone to oil consumption if not maintained properly. Timing belt replacement intervals are critical for interference engines.
